Polymer Masonry Unit and Method Therefor

ABSTRACT

A polymer-based compound, useful as a polymer masonry unit is disclosed that can include a polymer added to a quarry byproduct to manufacture a quality brick unit. The present disclosure solves the technological problem of providing a structurally sound brick or concrete alternative without the need for kiln firing, using traditionally unusable waste material. By combining quarry byproduct and a polymer, a polymer masonry unit can be fabricated having compressive strength and architectural utility. In one exemplary embodiment, fiber elements can be added to the byproduct and polymer mixture to increase structural stability. The present disclosure improves the performance of the system itself by providing a basic block or brick unit using an environmentally responsible manufacturing process that reduces cost and waste. The manufacturing process includes a polymer/base material that can be poured into molds that cures over a predetermined period, without the need for kiln firing.

CROSS-RFERENCE TO RELATED APPLICATIONS

The present application is a Divisional application of U.S. patentapplication Ser. No. 17/409,952, filed on Aug. 24, 2021, which claimspriority to U.S. Prov. App. Ser. No. 63/073,243, filed on Sep. 1, 2020,the entireties of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure generally relates to composite materials, andmore specifically to composite material including a rock base materialand a polymer.

BACKGROUND

Construction of civil infrastructure requires many types of differentcomponents. Stone, brick, steel, and concrete are just a few types ofmaterials found in a given edifice. The masonry-related elements (e.g.,stone, brick, and concrete) are widely utilized for their comparativelylow cost and high compression strength, allowing them to bear heavyloads and form foundations, floors, walls, columns, etc. Each of thesemasonry-related elements is obtained in a different way. For example,bricks are generally molded into rectangular cubes and then fired;concrete is generally a mixture of gravel or sand and cement which canharden when left stationary; and stone is mined, such as at rock quarrylocations.

With respect to bricks, traditional methods of brick creation sufferfrom many disadvantages that exacerbate environmental problems by addingto carbon emissions or creating structurally inferior products. Modern,fired, clay bricks are formed in one of three processes—soft mud, drypress, or extruded. Depending on the country, either the extruded orsoft mud method is the most common, since they are the most economical.Fired bricks are the strongest, most durable bricks today; however, theymust be burned in a kiln to make them durable. A kiln is typically usedto fire bricks between 1,800 to 2,400 degrees Fahrenheit. In many modernbrickworks, bricks are usually burned in a continuously-fired kiln,where the bricks are fired as they move slowly through the kiln onconveyors, rails, or kiln cars, which achieves a more consistent brickproduct. The bricks often have lime, ash, and organic matter added,which accelerates the burning process. Such process requires the addedexpense of kiln fabrication, fuel costs, and additives to accelerateburning. This kiln-firing process cooks the brick into a finished form,which makes it cure and draws out all of the liquid and all of the fluidthat might be inside of it to harden the brick. Kiln-firing bricks iscostly, as it requires some form of fuel to create the fire thatgenerates the immense heat. Such process requires additional resources,such as natural gas, propane, coal, wood, or other suitable material,which must be purchased, stored, and consumed.

With respect to concrete, the manufacture and use of concrete alsoengenders a wide range of environmental and social consequences. Forexample, production of cement, the major component of concrete, is aleading cause of carbon dioxide emissions; the cement industry is one ofthe three primary producers of carbon dioxide. This is largely due tothe need to sinter, e.g., limestone and clay at around 2,700 to 2,800degrees Fahrenheit—every ton of cement produced releases one ton ofcarbon dioxide into the atmosphere. Concrete additionally contributessignificantly to the urban heat island effect, and production ofconcrete masonry units also generates other harmful byproduct that cancause health concerns due to toxicity and radioactivity.

With respect to stone, while avoiding many of the issues associated withbrick and concrete (i.e., kiln firing, significant carbon emissions fromproduction, etc.), stone must generally be mined from the ground, suchas at a rock quarry, and mining stone can be strenuous and wasteful. Arock quarry is a type of open-pit mine in which stone, rock, oraggregate can be excavated from the ground. Many quarry stones such asmarble, granite, limestone, and sandstone are cut into larger slabs andremoved from the quarry. As slabs are cut from the quarry, waste isproduced. The production process for dimensional limestone produces anestimated 38% waste—material that does not meet job size andspecifications. This “waste” continues to accumulate daily andrepresents a sunk cost for the parent company raw material procurement.In the simplest terms, the stone ledge is exposed by removing theoverburden or dirt on top of the stone ledge. During the first phase, aproduction saw cuts the ledge to create stone blocks. As the saw cutsthe stone ledge, waste product is generated. Then, in the second phase,the blocks are processed into usable stone billets which are cut orprocessed into multiple slabs, where waste product is again generated.The stone slabs are then transported to another production areaplatform, where the finished good is fabricated; that process againgenerates additional waste product. Quarry byproducts are furtherproduced in crushing and washing operations during processing of crushedstone for use as construction aggregate. Three types of quarrybyproducts resulting from these operations include screenings, pondfines, and baghouse fines.

“Screenings” is a generic term used to designate the finer fraction ofcrushed stone that accumulates after primary and secondary crushing andseparation on a 4.75 mm (No. 4) sieve. The size distribution, particleshape, and other physical properties can be somewhat different from onequarry location to another, depending on the geological source of therock quarried, the crushing equipment used, and the method used forcoarse aggregate separation. Screenings generally contain freshlyfractured faces, have a fairly uniform gradation, and do not usuallycontain large quantities of plastic fines.

Pond fines refer to the fines obtained from the washing of a crushedstone aggregate. During production, the coarser size range (greater thanNo. 30 sieve) from washing may be recovered by means of a sand screwclassifier. The remainder of the fines in the overflow are discharged toa series of sequential settling ponds or basins, where they settle bygravity, sometimes with the help of flocculating polymers. Pond clay isa term usually used to describe waste fines derived from the washing ofnatural sand and gravel.

Some quarries operate as dry plants because of dry climatic conditionsor a lack of market for washed aggregate products. Dry plant operationrequires the use of dust collection systems, such as cyclones andbaghouses, to capture dusts generated during crushing operations. Thesedusts are referred to as baghouse fines.

It is estimated that at least 159 million metric tons (175 million tons)of quarry byproducts continue to be generated each year, mostly fromcrushed stone production operations. As much as 3.6 billion metric tons(4 billion tons) of quarry byproducts have probably accumulated.Currently, the only options for handling byproduct are to continuepiling the byproduct into a mountain or crush it for use as crushedaggregate product. While quarry byproduct has historically been utilizedby the industry to produce aggregate material, the primary endpoint hasbeen road construction. Specifically, with respect to the fabrication oflimestone, such processing creates a fair amount of waste that has verylimited application—limestone-based aggregate is typically not hardenough or dense enough to use for roadway base as a stand-alonematerial. For example, the Texas Department of Transportation (TXDOT)standards require aggregate to be a grade 1 or 2 specification for majorthoroughfares, and limestone-based aggregate produced from most Texaslimestone generally grades at TXDOT specification 3 or 4, which is toosoft for major thoroughfares and generally only acceptable for, e.g.,county roads and foundation base. From a byproduct recycling standpoint,however, the foundation base of choice in many markets does not utilizethe limestone aggregate, as a general rule.

The exact quantity of quarry byproducts that are being recycled is notknown. Very little of the 159 million metric tons (175 million ton)produced annually is thought to be used, especially the pond fines. In arecent survey, three states (Arizona, Illinois, and Missouri) indicatedthat quarry byproducts have been used as an embankment material andthree other states (Florida, Georgia, and Vermont) indicated some use ofquarry byproducts in base or subbase applications. Some use has beenmade of limestone screenings as agricultural limestone, and baghousefines from quarry sources have been used as mineral filler in asphaltpaving. However, virtually all of the quarry byproducts generated aredisposed of at the quarry source—screenings are stockpiled in a dry ordamp form; pond fines are conveyed in slurry form to settling ponds;baghouse fines are usually sluiced into settling ponds.

SUMMARY

The present disclosure achieves technical advantages as a PolymerMasonry Unit (PMU) that can include a polymer added to a quarrybyproduct, such as a limestone aggregate, to manufacture a quality brickunit. In one embodiment, the present disclosure can avoid a kiln-firingprocess, which is costly, creates waste, and consumes significantenergy. In another embodiment, the present disclosure can avoid the useof cement in forming construction units. In another embodiment, thepresent disclosure can utilize a mold infusion method thatadvantageously does not waste those resources or add the expense ofthose resources and does not create a larger carbon footprint by burningand smoke expulsion.

The present disclosure solves the technological problem of providing astructurally sound brick or concrete alternative without the need forkiln firing, using traditionally unusable waste material. By combiningquarry byproduct and a polymer, a polymer masonry unit can be fabricatedhaving compressive strength and architectural utility. In one exemplaryembodiment, fiber elements can be added to the byproduct and polymermixture to increase structural stability. Fiber elements can includehemp, glass, sand, cotton stalks or other plant fibers.

The present disclosure improves the performance of the system itself byproviding a basic block or brick unit using an environmentallyresponsible manufacturing process that reduces cost and waste. In oneembodiment, the manufacturing process includes a polymer/base materialthat can be poured into molds that cures over a predetermined period,without the need for kiln firing. In another embodiment, by using quarrybyproduct to fabricate polymer masonry units, the manufacturing of thepolymer masonry unit can be environmentally benign, as quarry byproductgenerally does not contain any elements that would be harmful to theenvironment.

The present disclosure offers significant advantages over traditionalconcrete and other building unit components. For example, a polymermasonry unit in accordance with the present disclosure can be fabricatedwithout application of a heat source. In another example, a polymermasonry unit mixture (e.g., a slurry that can be molded and/or dried,such as to make a polymer masonry unit), can have broad applicability.For example, polymer masonry unit mixture can be formed in molds tocreate face brick replacement blocks, poured as a concrete replacement,roadway material replacement, sculpture base, or other suitable materialreplacement. In one exemplary embodiment, given the consistency of themixture, the mixture can be used in 3-D printing applications where thismixture is operably coupled to a computer having a raster or vector filethat can control the positioning and operation of a nozzle/aperturedevice that can deliver precise quantities of the mixture to preciselocations. The location of the nozzle/aperture device can be operablycoupled to a mechanical positioning system, such as a track and servomotor frame, and controlled by the computer. The mixture can then becured into the final piece.

In one embodiment, the present disclosure can include aspecifically-formulated mixture that can yield a polymer brick unit thatcan, in one embodiment, serve as a replacement for bricks or concrete.For example, a polymer masonry unit in accordance with the presentdisclosure can have significant compression strength, such that it canarise to or exceed ASTM standards. In another embodiment, a polymermasonry unit composition can require a specific amount and/or range ofpolymer to achieve desired qualities. For example, it has been observedthat a specific amount of polymer must be used, or the polymer masonryunit could be unstable, brittle, or un-settleable. In one embodiment, apolymer masonry unit mixture comprising greater than, e.g., 10% byweight of polymer has been observed to yield a polymer masonry unit withcompromised structural integrity, such that the polymer masonry unitmixture cannot retain a shape of a modular brick mold. In anotherembodiment, a polymer masonry unit mixture comprising less than 1% byweight of polymer can yield a polymer masonry unit that is unable towithstand compression forces, such that the polymer masonry unit cannotbe a suitable construction material.

In another embodiment, polymer masonry unit mixture can be thick butmalleable, and wet and formable so it can be manipulated. In anotherembodiment, the manipulation period can be limited, such as once itbegins to cure and harden. In one exemplary embodiment, the cure timecan be within 24 hours. In one exemplary embodiment, the cure time canbe between 48 hours to 72 hours. In one embodiment, and such as can bedue to the fluid nature of the mixture, the mixture can also be sprayed.In one exemplary embodiment, the mixture can be sprayed onto the surfaceof a house. In another exemplary embodiment, color can be added to themixture. For example, color can be added to the mixture during themixing process and the colored mixture can be sprayed onto a surface.Alternatively, polymer masonry units can be traditionally painted and/orsealed. In another embodiment, another benefit of the polymer masonryunit is the R-rating of the material. The heat absorption and radiationproperties of brick and concrete are significantly greater than those ofthe polymer masonry unit.

In one embodiment, the present disclosure can include a method offorming a polymer masonry unit, the method comprising the steps of:determining a unit size; determining an amount of rock base material;determining a target moisture content; determining a target polymercontent; calculating a predicted wet mixture weight; determining, usingthe target moisture content, the predicted wet mixture weight, and thetarget polymer content, an amount of polymer and an amount of water;mixing the amount of rock base material, the amount of water, and theamount of polymer together to form a unit mixture having a wet mixtureweight; applying the unit mixture to a mold; and drying the unitmixture, wherein the amount of polymer comprises 1-10% of the wetmixture weight, wherein the amount of aggregate comprises 80-90% of thewet mixture weight, wherein the amount of water comprises 1-10% of thewet mixture weight. In another embodiment, the target moisture contentcan range from 8-20% of the wet mixture weight.

In another embodiment, the present disclosure can include a method offorming a polymer masonry unit, the method comprising the steps of:mixing together a rock base material, a polymer, and water to form amixture having a wet mixture weight; pouring the mixture into a mold;and drying the mixture, wherein the polymer is a styrene-butadiene-basedpolymer, wherein the polymer comprises 1-10% of the wet mixture weight.In one embodiment, the rock base material can be a calcium carbonateaggregate. In another embodiment, the rock base material can comprise80-90% of the wet mixture weight. In another embodiment, the water cancomprise 1-10% of the wet mixture weight. In another embodiment, themixture can be dried without a heat source. In another embodiment, themixture can be dried with an oven. For example, the oven drying can beat a drying temperature between 120-180 degrees, or other suitablerange. In another embodiment, the method can further comprise the stepof applying a glaze to the mixture. For example, the glaze can beapplied to the mixture to decrease environmental water absorption. Inanother embodiment, the mixture can have a moisture content from 8-20%of the wet mixture weight. In another embodiment, the method can furthercomprise the step of creating a void in the mixture. For example, thevoid can be shaped and sized to provide an aesthetic or functionaleffect suited to a specific application.

In another embodiment, the present disclosure can include a polymermasonry unit comprising a polymer and a quarry byproduct, wherein thepolymer comprises 1-10% of a weight of the unit, and the quarrybyproduct comprises 90-99% of the weight of the unit. In anotherembodiment, the quarry byproduct can be calcium carbonate aggregate. Inanother embodiment, the polymer can be an acrylic copolymer-basedpolymer. In another embodiment, the polymer can be astyrene-butadiene-based polymer. In another embodiment, 5-15% of thequarry byproduct can have a particle size of at least 4750 microns. Inanother embodiment, 10-20% of the quarry byproduct can have a particlesize ranging from 2360 microns to 4750 microns. In another embodiment,25-35% of the quarry byproduct can have a particle size ranging from 600microns to 2360 microns. In another embodiment, 30-40% of the quarrybyproduct can have a particle size ranging from 150 microns to 600microns. In another embodiment, 1-10% of the quarry byproduct can have aparticle size ranging from 75 microns to 150 microns.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be readily understood by the followingdetailed description, taken in conjunction with the accompanyingdrawings that illustrate, by way of example, the principles of thepresent disclosure. The drawings illustrate the design and utility ofone or more exemplary embodiments of the present disclosure, in whichlike elements are referred to by like reference numbers or symbols. Theobjects and elements in the drawings are not necessarily drawn to scale,proportion, or precise positional relationship. Instead, emphasis isfocused on illustrating the principles of the present disclosure.

FIG. 1 illustrates a perspective view of an exemplary stone quarry, inaccordance with one or more exemplary embodiments of the presentdisclosure;

FIG. 2 illustrates a perspective view of a quarry byproduct mound, inaccordance with one or more exemplary embodiments of the presentdisclosure;

FIG. 3 illustrates a perspective view of a polymer masonry unit mold, inaccordance with one or more exemplary embodiments of the presentdisclosure;

FIG. 4 illustrates a perspective view of a polymer masonry unit, inaccordance with one or more exemplary embodiments of the presentdisclosure;

FIG. 5 illustrates an exemplary byproduct particle size distribution, inaccordance with one or more exemplary embodiments of the presentdisclosure;

FIG. 6 illustrates an exemplary polymer masonry unit mixture compositiondistribution, in accordance with one or more exemplary embodiments ofthe present disclosure; and

FIG. 7 illustrates and exemplary method of forming a polymer masonryunit, in accordance with one or more exemplary embodiments of thepresent disclosure.

DETAILED DESCRIPTION

The present disclosure will be readily understood by the followingdetailed description, taken in conjunction with the accompanyingdrawings that illustrate, by way of example, the principles of thepresent disclosure. The drawings illustrate the design and utility ofone or more exemplary embodiments of the present disclosure, in whichlike elements are referred to by like reference numbers or symbols. Theobjects and elements in the drawings are not necessarily drawn to scale,proportion, or precise positional relationship. Instead, emphasis isfocused on illustrating the principles of the present disclosure.

FIG. 1 illustrates a perspective view of an exemplary stone quarry 100in accordance with one or more embodiments of the present disclosure.Significant quarry byproduct (rock base material) (stone quarrybyproduct) (aggregate) (stone quarry aggregate) 102 can be generated,such as during crushing and washing operations. In one embodiment, therecan be three types of quarry byproducts resulting from these operations:screenings, pond fines, and baghouse fines. In another embodiment, thequarry byproduct 102 generated from these operations can be similar inconcept to sawdust but can include fine dust and small stone fragments.In another embodiment, quarry byproduct 102 can also be generated byhydraulically splitting the stone billet or chipping it to fabricate thefinished goods. In another embodiment, quarry byproduct 102 can take theform of remnants of larger waste material that cannot be used in a givenproject. In one embodiment, such quarry byproduct 102 can be mixed witha polymer and/or for fabricating a polymer masonry unit. In anotherembodiment, the quarry byproduct 102 can be filtered to removeexcessively large stone fragments. In one exemplary embodiment, thequarry byproduct 102 can be calcium carbonate (calcium carbonateaggregate). In one embodiment, the quarry byproduct 102 can limestonebyproduct. In one exemplary embodiment, the byproduct can be limestone.In one embodiment, quarry byproduct 102 (e.g., limestone byproduct) canbe 40 parts per million calcium, which makes it 100% calcium carbonate.In one embodiment, the molecular composition and/or calcium content canbe important—for example, 100% calcium carbonate can be considered apure element that is less susceptible to degradation. In one embodiment,calcium carbonate can have the same characteristics as the limestoneslab. In another embodiment, quarry byproduct 102 can be any stonequarry byproduct, rock dust, stone fragments, or other suitablerock-based byproduct.

In another exemplary embodiment, saws (e.g., Vermeer saws) can activelymine surface rock at a stone quarry 100 into blocks used for production.In one embodiment, these blocks can then be fabricated with additionalsaws (e.g., Cobra saws) that can transform blocks into slabs ofdifferent heights, such as from 1″ to 16″. In another embodiment, theseslabs can then be introduced into the finishing stages where they arerefined into chopped stone or sawed stone. In another embodiment, thesefinished goods can then be marketed and sold as smooth or chopped stonein full veneer with a thickness ranging from, e.g., 3-5″ in width toaccommodate a brick ledge used in commercial and residentialconstruction. In another embodiment, these same blocks can be used asthin veneer applications ranging in thickness from, e.g., 1-1.5″ andused in commercial and residential construction. In one example, stonequarry processes can generate an average of 38% waste depending on theprocess and application employed to produce the finished product.

FIG. 2 illustrates a perspective view of a quarry byproduct mound 200 ata rock quarry, in accordance with one or more exemplary embodiments ofthe present disclosure. In one embodiment, the quarry byproduct can belimestone byproduct that can be typically collected by piling it into amound. In one embodiment, the mound can continue to grow as quarryoperations continue. In another embodiment, once it rains, the excesscan set and harden. In another embodiment, quarry byproduct can beformed during sawing of a rock shelf, which can form a crevasse ortrail, such as saw trail 202. Generally, the aggregate 200 canaccumulate at these areas.

FIG. 3 illustrates a perspective view of a polymer masonry unit mold, inaccordance with one or more exemplary embodiments of the presentdisclosure. In one embodiment, the mold 300 can include a receptacle 302and a frame 304. In another embodiment, the mold 300 can include a door306 or other access point, such as to facilitate the removal of apolymer masonry unit from the mold 300. In another embodiment, mixingquarry byproduct with a polymer and water can create a mixture that canbe poured into the mold 300, or into any other suitable mold. In oneembodiment, the ingredients can be mixed until reaching the consistencyof a paste, (e.g., using a hand drill and a mixing attachment or othersuitable mixing process). In another embodiment, the mold 300,receptacle, 302, and/or frame 304 can be of any shape and can haveornamentation that can be impressed or embossed into the mixture. In oneembodiment, the mold 300 can be made of metal, plastic, or othersuitable material.

FIG. 4 illustrates a perspective view of a polymer masonry unit 400, inaccordance with one or more exemplary embodiments of the presentdisclosure. In one exemplary embodiment, the polymer masonry unit 400can include: quarry byproduct (e.g., 34 lbs. of limestone) mixed with apolymer (e.g., 1.2 ounces of an acrylic copolymer-based polymer) andwater (e.g., 8 ounces). In another exemplary embodiment, the quarrybyproduct can comprise granite, clay, gypsum, marble, slate, or othersuitable rock. In another exemplary embodiment, the polymer can compriseany natural or synthetic polymer. In another exemplary embodiment, thepaste can then be poured into a mold of approximate size 3″×3″×9″ up to6″×6″×24″ (or other suitable dimensions) and allowed to cure for apredetermined time period (e.g., 24 hours), without the application ofany heat. In another exemplary embodiment, the paste can be fully curedin 48 hours and a polymer masonry unit 400 (block or brick) can beextracted from the mold. In another embodiment, the polymer masonry unit400 can be cured with a heat source, such as an oven. In anotherexemplary embodiment, the fabrication methods of cutting, splitting,and/or sanding can be applied to the polymer masonry unit. In anotherembodiment, and advantageously, the characteristics and structuralstability of the polymer masonry unit 400 can match those of naturallimestone.

In one embodiment, the polymer masonry unit 400 can be structurallystable. In one exemplary embodiment, the polymer masonry unit can meetor exceed the ASTM standard for structural stability. In anotherexample, polymer masonry unit 400 can meet or exceed the ASTM standardsfor structural stability in regard to density in water absorption andspecific gravity and compressive strength, among others. In anotherembodiment, the polymer masonry unit 400 mixture can be an alternativeto concrete. In another embodiment, when the polymer masonry unit 400gets radiated, there can be no emissions, in contrast to concrete.

In one exemplary embodiment, the polymer masonry unit 400 can have thelook and feel of limestone. In another embodiment, the polymer masonryunit 400 can be sawed, hydraulically split with pressure, or cut by anyother suitable mechanism. In another embodiment, the polymer masonryunit 400 can be finished applying a coat of a polymer (such as the samepolymer that helps form the unit 400) on the surface of the polymermasonry unit, such as to seal the polymer masonry unit, and/or tominimize any powder or residue of the polymer masonry unit 400. Inanother embodiment, the polymer masonry unit 400 can be glazed, such aswith ceramic, polymer, or any other suitable material. In anotherembodiment, voids (cores) can be disposed within the polymer masonryunit 400, such as to modify a weight of the polymer masonry unit 400.

In another embodiment, the polymer masonry unit 400 can comprise certainamounts of rock base material, polymer, and water. For example, apolymer masonry unit 400 can comprise 1-10% polymer by weight. Inanother embodiment, a polymer masonry unit 400 can comprise 5-8% polymerby weight. In another embodiment, a polymer masonry unit 400 cancomprise less than 10% polymer by weight. In another embodiment, apolymer masonry unit 400 can comprise more than 3% polymer by weight. Inanother embodiment, the polymer masonry unit can comprise 90% rock basematerial by weight. In another embodiment, the polymer masonry unit cancomprise 90-91.5% rock base material by weight. In another embodiment,the polymer masonry unit can comprise 91-92% rock base material byweight. In another embodiment, the polymer masonry unit can comprise92-94% rock base material by weight.

In another embodiment, quarry byproduct like that used in the polymermasonry unit 400 can have a particular liquid limit, a particularplastic limit, and/or a particular plasticity index. For example, thequarry byproduct can have a liquid limit from 15-25%. In anotherembodiment, the quarry byproduct can have a plastic limit of 10-20%. Inanother embodiment, the quarry byproduct can have a plasticity index of1-10%. In another embodiment, quarry byproduct can have any liquidlimit, plastic limit, and/plasticity index such that the quarrybyproduct is suitable to be utilized in a polymer masonry unit. Inanother embodiment, quarry byproduct can include any other sort ofmeasurable index, including liquidity index, consistency index, flowindex, toughness index, activity, or any other index, measurement, orconstant associate with aggregate, soil, or any other particulatematter. In another embodiment, the polymer can be, e.g., T-PRO 500® byTerratech Inc. In another embodiment, the polymer can be a water-basedemulsion of acrylic copolymer designed specifically for stabilizationand dust suppression for a variety of soil types. In another embodiment,the polymer can be eco-safe, non-toxic, and specifically formulated tointeract with soil chemistry and create high strength, durable, waterresistant bonds.

FIG. 5 depicts another embodiment of the present disclosure. In oneembodiment, rock base material can include particles of severaldifferent sizes. For example, a quarry byproduct particle sizedistribution 500 can include particles of 4750 microns and larger,particles of 2360 microns to 4750 microns, particles of 600 microns to2360 microns, particles from 150 microns to 600 microns, particles from75 microns to 150 microns, particles from 53 microns to 75 microns,and/or particles smaller than 53 microns. In another embodiment, 5-15%by weight of particles of a rock base material can include particles of4750 microns and larger. In another embodiment, 10-20% by weight ofparticles of a rock base material can include particles of 2360 micronsto 4750 microns. In another embodiment, 25-35% by weight of particles ofa rock base material can include particles of 600 microns to 2360microns. In another embodiment, 30-40% by weight of particles of a rockbase material can include particles from 150 microns to 600 microns. Inanother embodiment, 1-10% by weight of particles of a rock base materialcan include particles from 75 microns to 150 microns. In anotherembodiment, 0-1% by weight of particles of a rock base material caninclude particles from 53 microns to 75 microns. In another embodiment,0-1% by weight of particles of a rock base material can include and/orparticles smaller than 53 microns.

FIG. 6 depicts another embodiment of the present disclosure. Acomposition of a polymer masonry unit can include aggregate, polymer,and water. In one embodiment, a polymer masonry unit slurry composition(polymer masonry unit mixture composition) 600 can be described by acontent of materials included in a mixture (slurry) that can harden intoa polymer masonry unit. For example, a polymer masonry unit slurrycomposition 600 can be described by the comparative weights of materialsincluded in a mixture viewed as a percentage of the total weight of theun-hardened mixture. For example, a polymer masonry unit slurry caninclude 10% by weight of water, 10% by weight of polymer, and 80% byweight of aggregate when the slurry is initially mixed together. In oneembodiment, as the slurry hardens, the weight ratios can change, such asdue to evaporation, seepage, etc. In one embodiment, a polymer masonryunit can be referred to as, e.g., a “10%” unit, such as if a polymermasonry unit slurry included 10% by weight polymer.

In one embodiment, 2-8% of a weight of the polymer masonry unit slurrycomposition 600 can be polymer. In one embodiment, 3-7% of a weight ofthe polymer masonry unit slurry composition 600 can be polymer. In oneembodiment, substantially 2.5-3.5% of a weight of the polymer masonryunit slurry composition 600 can be polymer. In one embodiment,substantially 3.5-4.5% of a weight of the polymer masonry unit slurrycomposition 600 can be polymer. In one embodiment, 5% of a weight of thepolymer masonry unit slurry composition 600 can be polymer. In oneembodiment, 5.5-6% of a weight of the polymer masonry unit slurrycomposition 600 can be polymer. In one embodiment, 6-7.5% of a weight ofthe polymer masonry unit slurry composition 600 can be polymer. In oneembodiment, 7.5-8.8% of a weight of the polymer masonry unit slurrycomposition 600 can be polymer. In one embodiment, substantially 9% of aweight of the polymer masonry unit slurry composition 600 can bepolymer. In one embodiment, substantially 10% of a weight of the polymermasonry unit slurry composition 600 can be polymer.

In another embodiment, the polymer masonry unit mixture composition 600can include a moisture content. In one embodiment, the moisture contentcan refer to an amount of fluid within the mixture, such as compared tothe totality of the mixture. In one embodiment, the moisture content canbe measured as a percent weight of the total mixture weight. Forexample, the polymer masonry unit slurry composition 600 can have amoisture content ranging from 1-20%; in another example, this can referto the weight of the mixture that can be accounted for by a fluid in themixture. In another embodiment, the moisture content of the composition600 can include water as fluid. In another embodiment, the moisturecontent of the composition 600 can include a polymer as a fluid. Inanother embodiment, the moisture content of the composition 600 caninclude both water and a polymer as a fluid. For example, the amount ofwater and the amount of polymer in the composition 600 can be combinedto account for a moisture content of the composition 600. In anotherexample, if water comprises 4% of the composition 600 by weight, and thepolymer comprises 10% of the composition 600 by weight, then themoisture content of the composition 600 can be, e.g., 14%.

In another embodiment, the moisture content of the composition 600 canbe 1-5%. In another embodiment, the moisture content of the composition600 can be 5-10%. In another embodiment, the moisture content of thecomposition 600 can be 10-15%. In another embodiment, the moisturecontent of the composition 600 can be 15-20%. In another embodiment, themoisture content 600 can be of any amount suitable to enable thecompaction and/or molding of the composition 600, such as, e.g., into apolymer masonry unit. In another embodiment, the moisture content cancorrespond to an optimal moisture content of a particular aggregate,such as can be determined by, e.g., a Proctor compaction test. Inanother embodiment, a moisture content range can include an optimalmoisture content of a particular aggregate, such as can be determinedby, e.g., a Proctor compaction test.

FIG. 7 depicts another embodiment of the present disclosure. A method offorming a polymer masonry unit 700 can begin at step 702, where a unitsize can be determined. For example, a polymer masonry unit can be ofany suitable size for any suitable construction. In one embodiment, aunit can be 3⅝ inches by 2¼ inches by 7⅝ inches. In another embodiment,a unit can be 2¾ inches by 2¾ inches by 7⅝ inches. In anotherembodiment, a unit can be 2 ¾ inches by 2⅝ inches by 9⅝ inches. In oneembodiment, a unit can take the form of a tile. In another embodiment,the unit can include any dimensions.

At step 704, In step 704, the amount of rock base material can bedetermined. In one embodiment, determining a unit size can assist indetermining an amount of rock base material to be used. For example, aunit of a particular size can require a particular amount of rock basematerial. For example, a unit size of 3⅝ inches by 2¼ inches by 7⅝inches can require 12.5 pounds of rock base material. In one embodiment,the rock base material can comprise the vast majority of the volume of agiven unit, such as because the amount of water and/or polymer iscomparatively small, and/or because the water and/or polymer can fill inspaces between rock base material particles such that the water and/orpolymer does not substantially affect a volume and/or size of a mixtureof rock base material, water, and polymer.

At step 706, a target moisture content can be determined. For example, arock base material can have an optimal moisture content at which it willachieve a maximum dry density when compacted and dried. In oneembodiment, a target moisture content can be from 8-20%, as calculatedby dividing the weight of moisture by the total weight of rock basematerial with moisture in the rock base material. In another embodiment,the target moisture content can be from 12-16%. In another embodiment,the target moisture content can be in any range or amount that canfacilitate the compaction and sufficient dry density of the rock basematerial.

At step 708, a target polymer content can be determined. For example, aunit and/or unit mixture can have varying degrees of polymer as comparedto the rock base material and/or water that can lend distinct propertiesto a given unit. In one embodiment, including less polymer can lead to amore brittle unit. In another embodiment, using more polymer can lead toa more malleable unit. In one embodiment, a specific polymer content ofa unit mixture and/or unit can provide optimal compression strength. Inone embodiment, a target polymer content can be from 1-10% of a wetmixture weight. In another embodiment, a target polymer content can beless than 8%. In another embodiment, a target polymer content can bemore than 2%.

At step 710, a predicted mixture weight (predicted wet mixture weight)can be calculated. For example, the amount of rock base materialdetermined at step 704 and the target moisture content determined atstep 706 can be utilized to calculate the predicted mixture weight. Forexample, if the rock base material amount and/or weight is known, and itis also known what the moisture content should be to achieve the targetmoisture content, a predicted wet mixture weight can thereby becalculated.

At step 712, an amount of polymer can be determined. For example, thetarget polymer content determined at step 708 can be utilized with thepredicted mixture weight calculated at step 710 to arrive at an amountof polymer. For example, if a predicted mixture weight is 13 pounds, anda target polymer content is 3%, it can be determined that 3% of the 13pounds should be the amount of polymer.

At step 714, an amount of water can be determined. In one example, anamount of water be determined using amount of polymer and the targetmoisture content. For example, the amount of polymer can be included ina moisture content consideration—in other words, a moisture content caninclude polymer that provides fluid that can be considered moisture. Inanother embodiment, an amount of polymer can comprise a portion of themoisture content, and an amount of water can comprise the remainder ofthe moisture content not accounted for by the polymer. For example, andin one embodiment, if a target moisture content is 10% by weight of thewet unit mixture, and the amount of polymer determined at step 712 is 3%by weight of the wet unit mixture (which can, e.g., correspond to thetarget polymer content determined at step 708), 30% of the totalmoisture content can be accounted for by the polymer. In one embodiment,an amount of water can then be determined to be 7% by weight of the wetunit mixture, such that the entire moisture content can be 10% of thewet unit mixture. In another embodiment, the amount of water can be anyamount necessary to add with the polymer to achieve the target moisturecontent.

At step 716, the amount of rock base material determined at step 704,the amount of polymer determined at step 712, and the amount of waterdetermined at step 714 can be combined. In one embodiment, the amount ofwater and the amount of polymer can be combined first and subsequentlyadded to the amount of rock base material. In another embodiment, thethree components can be combined simultaneously. In another embodiment,a portion of a mixture of water and polymer can first be added (e.g., toa receptacle, such as receptacle 302 of mold 300 or to any othersuitable receptacle), followed by a portion of the amount of rock basematerial, and the water, polymer, and rock base material can then beadded alternately until the entire amounts of the materials areutilized. In another embodiment, the water, polymer, and rock basematerial can be combined in any order or manner suitable to facilitatethe mixing of the materials, such as to, in one embodiment, form asubstantially homogenous mixture.

At step 718, the combined materials from step 716 can be mixed togetherto form a unit mixture. In one embodiment, the unit mixture can be mixeduntil it is substantially homogenous. In another embodiment, the unitmixture can have a weight (wet mixture weight). The combination can bemixed in any suitable receptacle, such as a bucket, bowl, tough, or anyother suitable receptacle. In another embodiment, the combination can bemixed in, e.g., a receptacle, such as receptacle 302 of mold 300. Inanother embodiment, steps 716 and 718 can be performed simultaneously.

At step 720, the mixture formed at step 718 can be molded. For example,the mixture can be applied to a receptacle of a mold (e.g., receptacle302 of mold 300). In one embodiment, the mixture can be added such thatit lays in the mold in a uniform fashion, such as to, e.g., facilitatemolding of the mixture into a uniform shape.

At step 722, the mixture can be partially dried. In one embodiment, themixture can be air dried, such as until the mixture is substantiallysolid, such that it can be removed from the mold. In another embodiment,the mixture can be dried in an oven or with any other suitable heatsource.

At step 724, a glaze can be applied to the mixture. In one embodiment,the glaze can be a polymer (such as, e.g., the polymer utilized in themixture), a ceramic glaze, or any other suitable glaze. In anotherembodiment, the glaze can be any material suitable to facilitate thesealing of the mixture, such as against moisture.

At step 726, the drying process can be completed to form a polymermasonry unit. For example, the mixture can be subjected to further airdrying. In another embodiment, the partially dried mixture can be ovendried. In another embodiment, the mixture can be dried with a heatsource. In another embodiment, the mixture can be dried without a heatsource.

It will be understood by those having skill in the art that severalmethods are available to determine characteristics of given rock basematerial in accordance with the principles of the present disclosure.For example, a sieve analysis test can be used to determine a particlesize distribution of a quarry byproduct. In another example, a Proctorcompaction test can be used to determine an optimal moisture content(which can guide, e.g., a target moisture content) at which a givenaggregate will become most dense and achieve its maximum dry density. Inanother embodiment, an Atterberg test can be utilized to determineliquid limits, plastic limits, plasticity indices, or any other suitableindices, measurements, or constants related to critical water contentsof, e.g., a quarry byproduct.

In another embodiment, polymer masonry units in accordance with theprinciples of the present disclosure can withstand compression. Forexample, a unit can withstand, in one embodiment, up to 4000 PSI. Inanother embodiment, a polymer masonry unit in accordance with theprinciples of the present disclosure can withstand any amount ofcompression necessary to allow the unit to pass, for example, ASTMstandards with respect to compression strength.

Persons skilled in the art will readily understand that the advantagesand objectives disclosed herein would not be possible without theparticular combination of structural components and mechanisms assembledin this inventive system and described above.

The present disclosure achieves at least the following advantages:

1. New use for quarry byproduct;

2. Construction unit whose manufacture is environmentally friendly;

3. Brick unit that does not require a kiln to cure; and

4. Recycles quarry byproduct into a construction unit capable ofreplacing traditional bricks.

The description in this patent document should not be read as implyingthat any particular element, step, or function can be an essential orcritical element that must be included in the claim scope. Also, none ofthe claims can be intended to invoke 35 U.S.C. § 112(f) with respect toany of the appended claims or claim elements unless the exact words“means for” or “step for” are explicitly used in the particular claim,followed by a participle phrase identifying a function. Use of termssuch as (but not limited to) “mechanism,” “module,” “device,” “unit,”“component,” “element,” “member,” “apparatus,” “machine,” “system,”“processor,” “processing device,” or “controller” within a claim can beunderstood and intended to refer to structures known to those skilled inthe relevant art, as further modified or enhanced by the features of theclaims themselves, and can be not intended to invoke 35 U.S.C. § 112(f).

The disclosure may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. For example, eachof the new structures described herein, may be modified to suitparticular local variations or requirements while retaining their basicconfigurations or structural relationships with each other or whileperforming the same or similar functions described herein. The presentembodiments are therefore to be considered in all respects asillustrative and not restrictive. Accordingly, the scope of theinventions can be established by the appended claims rather than by theforegoing description. All changes which come within the meaning andrange of equivalency of the claims are therefore intended to be embracedtherein. Further, the individual elements of the claims are notwell-understood, routine, or conventional. Instead, the claims aredirected to the unconventional inventive concept described in thespecification.

While the disclosure has described a number of embodiments, it is notthus limited and is susceptible to various changes and modificationswithout departing from the spirit thereof. Persons skilled in the artwill understand that this concept is susceptible to various changes andmodifications, and may be implemented or adapted readily to other typesof environments. Further, the individual elements of the claims are notwell-understood, routine, or conventional. Instead, the claims aredirected to the unconventional inventive concept described in thespecification.

1. A method of forming a polymer masonry unit, the method comprising thesteps of: determining a unit size; determining an amount of aggregateincluding rock base material; determining a target moisture content;determining a target polymer content; calculating a predicted wetmixture weight; determining, using the target moisture content, thepredicted wet mixture weight, and the target polymer content, an amountof polymer and an amount of water; mixing the amount of aggregateincluding the rock base material, the amount of water, and the amount ofpolymer together to form a unit mixture having a wet mixture weight;applying the unit mixture to a mold; and drying the unit mixture,wherein the amount of polymer comprises 1-10% of the wet mixture weight,wherein the rock base material is a calcium carbonate aggregate.
 2. Themethod of claim 1, wherein the target moisture content ranges from 8-20%of the wet mixture weight.
 3. The method of claim 1, wherein the mixtureis dried with an oven.
 4. The method of claim 1, further comprising thestep of applying a glaze to the mixture.
 5. The method of claim 1,wherein the mixture is dried without a heat source.
 6. The method ofclaim 1, further comprising the step of creating a void in the mixture.7. A method of forming a polymer masonry unit, the method comprising thesteps of: mixing together a rock base material, a polymer, and water toform a mixture having a wet mixture weight, wherein an amount of thewater to be mixed is determined based on a target moisture content forthe mixture; pouring the mixture into a mold; and drying the mixture,wherein the polymer comprises 1-10% of the wet mixture weight whereinthe rock base material is a calcium carbonate aggregate.
 8. The methodof claim 7, wherein the calcium carbonate aggregate is 40 parts permillion calcium.
 9. The method of claim 7, wherein the rock basematerial comprises 80-90% of the wet mixture weight.
 10. The method ofclaim 7, wherein the water comprises 1-10% of the wet mixture weight.11. The method of claim 7, wherein the mixture is dried without a heatsource.
 12. The method of claim 7, wherein the mixture is dried with anoven.
 13. The method of claim 7, further comprising the step of applyinga glaze to the mixture.
 14. The method of claim 7, wherein the mixturehas a moisture content from 8-20% of the wet mixture weight.
 15. Themethod of claim 7, further comprising the step of creating a void in themixture.
 16. The method of claim 7, wherein the polymer is astyrene-butadiene-based polymer.
 17. The method of claim 1, whereindetermining a target moisture content includes determining a targetamount of fluid within the unit mixture.
 18. The method of claim 17,wherein the polymer is in a fluid form, and wherein the target amount offluid includes the amount of water and the amount of polymer.
 19. Themethod of claim 7, wherein the target moisture content for the mixtureincludes a target amount of fluid within the mixture.
 20. The method ofclaim 19, wherein the polymer is in a fluid form, and wherein the targetamount of fluid includes the water and the polymer.